Running shoes, hiking shoes and boots, snowboard boots, alpine boots, hiking boots, and the like, having waterproof/breathable moisture transfer characteristics

ABSTRACT

The waterproof/breathable moisture transfer liner for a running and hiking shoe includes an inner liner selected from technically advanced fabrics which are carefully selected. A series of layers are provided outside the inner liner including foam material layers, breathable membranes, a supportive mesh or a moldable foam, and an outer shell fabric. The applicability of the liner to alpine, snowboard boots, cross country, hiking boots, protective gear and helmets, along with appropriate variations for each application.

FIELD OF THE INVENTION

The present invention relates to a variety of shoes and boots used in avariety of applications. For example, the present invention may beemployed in a variety of applications including running shoes, litehiking shoes and hiking boots, snowboard boots, alpine boots, and thelike. The shoes and boots are breathable and waterproof to increasecomfort for the runner, hiker or rider, etc. These shoes and bootsinclude liner that transfer moisture in a way never before accomplishedin the prior art.

BACKGROUND OF THE INVENTION

Various types of liners are known from the prior art. However, theseliners do not provide the advantages realized by the present invention.The present inventor has recognized the problems faced by runners,snowboarders, skiers and hikers and developed shoes, boots and liners toovercome such problems.

There is an on-going need for comfort, breathability, and support forrunning shoes, snowboard boots and alpine boots and linings therefor. Inprior designs, a rigid, non-breathable outer material, such as vinyl,foam, and nylon is often used. The inner liners have been leather,synthetic leather, nylon, or polyester blends which extremely limit theability to breathe or wick moisture away from a runner or rider's body.These materials have prevented the foot from breathing adequately.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a first portion of the liner according to a firstembodiment of the present invention.

FIG. 2 illustrates a second portion of the liner according to a firstembodiment of the present invention.

FIG. 3 illustrates an example of the liner according to the firstembodiment of the present invention.

FIG. 4 illustrates the liner shown in FIG. 3 which will form a part of arunning shoe, snowboard boot or alpine boot liner.

FIGS. 5(a) and 5(b) illustrate a sole portion of a liner constructedaccording to a preferred embodiment of the present invention.

FIGS. 6 and 7 illustrate a tongue portion of a shoe or snowboard bootconstructed according to the first embodiment of the present invention.

FIG. 8 illustrates a more detailed view of the liner portion used forthe tongue of FIGS. 6 and 7.

FIG. 9 illustrates a portion of the liner used in the upper cuff area.

FIG. 10 illustrates the travel of moisture through a reticulated foam,then a flexible mesh, into and through a breathable membrane accordingto the first embodiment of the present invention.

FIG. 11 illustrates the toe portion of a shoe, snowboard boot or alpineboot according to a preferred embodiment of the present invention.

FIG. 12 illustrates an overall drawing of a snowboard boot, soft alpine,alpine or hiking boot which will incorporate the liner of the presentinvention.

FIG. 13 illustrates an overall drawing of a running shoe.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the preferred embodiments of thepresent invention is undertaken in connection with the drawings. Thisdescription, while undertaken with respect to the disclosed embodiments,is intended to enable a variety of different applications and slightmodifications which form a part of the present invention. Morespecifically, many of the materials used in this lining system have beendeveloped relatively recently, and in many cases are still beingmodified and improved. Where possible, tradenames of specific productshave been used to assist in the understanding of the invention. Thelining system according to the present invention can be easily adaptedto accommodate further developments in these materials. For example,while the preferred embodiments are illustratively presented below as aspecific sequence of layers, it should be understood that one or more ofthese layers may be omitted depending upon the specific needs of anyapplication. In other words, it is not strictly necessary to have acertain number of foam layers just as that disclosed in the currentlypreferred embodiment. This also applies for the other elements that aredescribed. For the sake of conciseness, every possible combinationcontemplated by the inventor is not specifically enumerated. With thisin mind, the preferred embodiments currently envisioned are set forthbelow.

FIG. 1 illustrates a portion of the liner, or lining system, accordingto a first embodiment of the present invention. This embodiment isdirected to a liner for a running shoe which is generally non-removableor for a snowboard or alpine boot which is generally removable. Theliner may be non-removable in some embodiments. The various layers ofmaterials discussed below can be attached to one another in a number ofways, particularly by lamination, mechanical bonding (or stitch bondingsuch as that done by Tietex, Inc. or XYMED GROUP by DuPont®) or FossManufacturing, or the like, or a combination of lamination andmechanical bonding. Mechanical bonding can be performed using nylon,spandex or LYCRA® thread, or the like. As shown in FIG. 1, a first foammaterial (20) is provided between an inner liner (10) and a nonwovenattached to a second foam material (30). The inner liner (10) can beattached to the first foam material (20) by lamination or the like. Thesecond foam material (30) is a germicidal, reticulated and/or open cellfoam and has a thickness of approximately 1/20 to ¼ inch. All of thefoam materials used in the present invention are assumed to bebreathable and their thickness can be varied depending upon specificneeds. Alternatively, some of the foam materials can be replaced with agermicidal, hydrophilic open-cell foam. For example, a foam calledAQUAZONE or VPF (made by FOAMEX) may be used. Preferably, the AQUAZONEor VPF is attached to a non-woven top sheet made of wool, wood pulp,polyester, cotton, rayon, polypropylene, LYCRA®, spandex, lyocel,acetate or a combination of these, etc.

The inner liner (10) is preferably constructed using specific fabricspossessing certain desired characteristics. A list of fabrics which canbe employed depending upon the individual needs of their application aswell as the individual needs of each runner or rider is provided below.These fabrics may either be used individually or in combination and canbe double sided with one fiber on one side and another on the otherside. Variations for use in a running or hiking shoe, snowboard or softalpine or shell boot or liner are specifically recited.

The first fabric is an anti-microbial, anti-fungal polypropylene (alsoreferred to as polyolefin) LYCRA® blend (2%) with INNOVA fiber, or thelike. INNOVA is a continuous filament fiber (manufactured by DeercreekFabrics, Inc. or Coville, Inc.).

The second fabric is an anti-microbial, anti-fungal polypropylene havinga polyester or cotton backing, or the like (such as that manufactured byCoville, Inc.). For uses such as winter hiking, alpine boots, thepolyester or cotton backing can be replaced with wool, silk, acetate,lyocel or the like.

The third fabric is an anti-microbial, anti-fungal polypropylene/cottonblend with ALPHA fiber (such as that manufactured by Intex Fabrics,Inc.).

The fourth fabric is a field sensor polyester with waffle weaveconstruction (such as that manufactured by Toray and distributed by Yagi& Co., Inc.). Alternatively, a polyester material known as AQUA-DRY,manufactured by Teijin Shojin can be employed.

The fifth fabric is a hydrophilic anti-microbial DRI-LEX BABY KID orperforated material (such as that manufactured by Faytex Corp.).

The sixth fabric is a polyester looped terry (such as that manufacturedby Kronfli Spundale Mills, Inc.).

The seventh fabric is a sueded/sanded polyester microfiber material(distributed by Yagi & Co., Inc. and Teijin Shojin, Inc.).

The eighth fabric is POLAR TEC Series 2000, which is a wickable,moisture transfer fiber, containing LYCRA® and polypropylene. Thisfabric is also anti-microbial.

The ninth fabric is a moisture transfer fabric by Tietex, Inc.

The tenth fabric is a wool blend with a cotton, polyester, or the likebacking. Double faced knitted fabric

The eleventh fabric is nylon or nylon polyester blend treated with orwithout transfer dry fiber technology manufactured by Guilford Mills.

The twelve fabric is a spacer fabrics constructed of nylon, polyester,polyester or polypropylene blends manufactured by Malden Mills orDeercreek Fabrics or the like.

The thirteenth fabric is a polypropylene, polyester or acrylic blends.Chemically ionized synthetic fabrics by Sterling Fiber. (CYSTAR AF ECT.)

The fourteenth fabric is acrillan or DURASPUN acrylics fabrics byMonsanto.

Fifteen fabric is an acetate blend.

Other fabrics recommended are DRILINE by Milliken & Co. DRYWICK byAdidas, DRI F. I. T. by Nike, DRYLINER by Insport, DRY-LEX by Faytex,HYDROMOVE by Reebok International, HYDRASUEDE by Insport, M.C.S. byBurlington Mills, NATUREXX POLARTEC 100 series bi polar by Malden Mills,QUICK WICK Collection by Summit Knitting.

All synthetic fibers and fabrics may be treated with transfer dry fibertechnologies.

Finally, spacer fabrics, polyester or polyester blends manufactured byMalden Mills and others can be used. These are composite fabrics havinglayers of fibers.

All of these fabrics have good moisture transfer characteristics whichprevent damage to a runner or rider's foot by preventing excessivemoisture build-up.

The moisture transfer characteristics of the inner liner (10) causesmoisture vapors to pass from a runner or rider's body through the innerliner (10) where it then comes into contact with the first foam material(20). The moisture vapors travel through the first foam material (20)and come into contact with the abutting nonwoven or second foam material(30).

The first foam material (20) may be a cellular elastomeric composite (asdescribed in U.S. Pat. No. 6,074,966 the disclosure of which herebyincorporated by reference), or the like. The cellular elastomericcomposite is formed in one process and is developed by FoxrunTechnology. Layer 20 is a 1/20″ to ⅛″ germicidal, reticulated foam (orgermicidal, hydrophilic flexible polyester, open-cell foam such asAQUAZONE or VPF, Or the like) backed with a non-woven top sheetcomprised of wool, wood pulp, rayon, cotton, polypropylene, lyocel,polyester, LYCRA®, spandex, or a combination there of or the like. Theelastomeric composite natural synthetic or blend fibers and foam arehydroentangled or fused together with water pressure.

Alternatively, foam material 20 can be a foam that is separate from thenon-woven top sheet and is attached to the non-woven top sheet bylamination, stitched, or ultrasonically bonded. The non-woven top sheet(when used) abuts the next layer of 1/20″ to ¼″ reticulated/hydrophilicflexible polyester, open cell foam, or second foam material 30. Thesecond foam material 30 may also be a germicidal, hydrophilic, open cell1/20″ to ¼″ foam, such as AQUAZONE or VPF or the like. The second foammaterial is preferably backed with a non-woven top sheet as mentionedabove. In fact, any of the foam materials discussed herein can be backedby such a non-woven top sheet and can be a flexible polyester open cellfoam. In fact the running shoe, hiking shoe, snowboard boot, soft alpineboot and shell boot or liner may utilize the composites to transfermoisture vapor. The composite system combines multiple layers of foamsand nonwovens in numerous locations to absorb, move and transfermoisture. This foam composite creates a one-way system that allowsmoisture to travel only in an outward direction. Also, many of the foammaterials are interchangeable depending upon specific needs.Alternatively, the foam materials can be flame laminated to a non-wovenapertured top sheet of wool, cotton, lyocel, polypropylene or polyester,or a blend thereof, for example. The apertured top sheet may also becoated with a foam or may have a polymer dot matrix applied that is apolymer with phase change material (which have reversible enhancedthermal properties).

For example, the first foam layer 20 may also be substituted with agermicidal, hydrophilic open-cell, 1/16″ to ⅛″ foam, such as AQUAZONE orVPF. The foam can also be backed by non-woven top sheet. Also, atemperature regulating membrane called Outlast, by Gateway Technologiescan be inserted between inner layer 10 and the first foam material 20,or applied to the fibers of layer 10.

Alternatively, Frisby Technologies can be embedded in the first opencell flexible polyester, hydrophilic foam layer 20 or placed in thesecond foam material 30. The hydrophilic foam is preferably AQUAZONE orVPF, but may be a Frisby product called COMFORTEMP, or the like.

The outlast membrane or coating can be placed on the other side of thefoam, outside the non-woven top sheet, if present. In fact, phase changetechnology by Outlast, Frisby, Freudenberg, Schoeller or Invista, or thelike may be combined with any foam, nonwoven or insulative layer and canbe on either side.

A number of patents have been issued to Triangle Research & DevelopmentCorp. disclosing details related to the processes now being employed byGateway Technologies and Frisby. For example, U.S. Pat. Nos. 4,756,958and 5,366,801 are directed to fibers and fabrics with reversibleenhanced thermal properties, respectively. The disclosures of these twopatents are hereby incorporated by reference. Other patents assigned toTriangle Research & Development Corp., that are related by subjectmatter and have overlapping inventorship, include U.S. Pat. Nos.5,415,22; 5,290,904; and 5,244,356. These patents are also herebyincorporated by reference.

Another patent, U.S. Pat. No. 5,499,460, which has overlappinginventorship with the above-mentioned patents, is directed to a moldablefoam insole with reversible enhanced thermal storage properties. Thedisclosure of this patent is hereby incorporated by reference, and isillustrative of one type of moldable foam that can be used as mentionedherein.

The nonwoven may as well by treated with a thermal enhancing technologyby Wisconsin Global Technologies or nanotechnology. Nanotechnology maybe used in any portion of this invention.

As shown in FIG. 2, a third foam material 50, which provides support andhas similar characteristics to the second foam material 30, allows themoisture vapors to continue their movement toward the outside. Thisthird foam material 50 may be a foam, a nonwoven or spacer fabric, orcombination thereof, is formed in certain areas to take necessary shapessuch as the shape of an ankle, heel cup and foot bones, and ispositioned so as to allow the moisture to pass through into subsequentelements, such as a waterproof/breathable membrane 70 and the outerlayer 80 of the overall lining system. The outer layer 80 is preferablywaterproofed by encapsulation or by using a waterproof/breathable finishor film. The third foam material 50 may alternatively be a spacer fabricby Muller or Malden or the like. The easily molded spacer fabric or thethird reticulated/open cell foam material 50 can be designed to providea well defined heel lift, and heel pocket. This invention develops thecomponents necessary to increase technical performance with theincreases support around the heel, toe, and ankle. For snowboard bootsor alpine boots, the toe box is from top to bottom, wider and moreflexible than in previous snowboard or alpine boots. The laminated ormechanically bonded foams and nonwovens under the heel support therunner and rider's lower back and allows for a comfortable stride. Withthis added comfort, the aggressive or recreational runner, hiker, rideror skier can achieve a higher level of continued performance. Spacerfabrics can be combined for improved performance.

As shown in FIG. 3, between the supporting second foam material 30 andthe third foam material 50 is a structural mesh 40 which can be a flexguard, for example such as one manufactured by Naltex or Conwed or thelike, that adds structural integrity to the lining system. A spacerfabric, moldable foam, or the like, may also be used in place of thisflex guard or mesh. Also, neither may be used in some circumstances. Themoldable foam, if not very breathable, can be made breathable bypuncturing. Alternatively, the moldable foam can be a reticulated orhydrophilic, open-cell structure, or the like. A non-woven top-sheet(with or without apertures) can be attached to the moldable foam. If aspacer fabric or moldable foam is used, then the second foam materialmay be omitted. Also, the moldable foam can be AQUAZONE or VPF.Preferably, for extreme sports applications the moldable foam or spacerfabrics are used instead of the flexible mesh as layer 40.

As mentioned earlier, the material 50 is preferably similar inconstruction to the second foam material, namely being eithergermicidal, reticulated and approximately 1/20″ to ¼ inch thick, orbeing germicidal, hydrophilic open-cell (for example AQUAZONE or VPF).This material is preferably laminated to a non-woven top sheet (whichmay or may not be apertured) comprised of wood pulp, lyocel, acetate,rayon, or cotton. The top sheet abuts the waterproof/breathable membrane70 or an encapsulated or coated outer fabric.

For snowboard, alpine and hiking boots, due to the cold weatherconditions, a combination of THERMOLITE(or THERMALOFT) or the like andfoam mechanically bonded or laminated together, or a foam and nonwoven,or SSOFTHERM inclusive of an open cell foam, or THERMOLITE with a spacerfabric or THERMOLITE by itself is preferably used for the third foammaterial 50. THERMOLITE, manufactured by DuPont®, is a thin insulationhaving a hollow polyester fiber laid in random layers with an acrylicbinder (loose felted) needle punched through the cross section to attachlayers and tie them down. Various types of THERMOLITE can be used, suchas THERMOLITE EXTREME, THERMOLOFT, MICROLOFT, TFI 2000 G/M2 or TFI 4000G/M2, etc.

Alternatively, a thermal nonwoven composite (by Foss Manufacturing)created with synthetic fibers having a open cell foam needle-punchedinto its internal structural layers can form layer 50, and abut layer60, an elastomeric composite, a open cell foam, another nonwoven, aspacer fabric, another thermal product such as THERMOLITE, Foss thermal,or layer 70 a breathable membrane or layer 80 the exterior fabric orsynthetic leather. Also, the foam can be combined with the fibers of thenonwoven or the nonwoven can be combined into the foam depending uponthe application and whether there is a need for cooling or warming. TheFoss composite may be next to outlast membrane or have the FrisbyTechnology embedded in the needled open cell foam applied. COMFORTEMP byFrisby Technology may also be needled into the existing Foss to thermalcomposite layer.

If encapsulation is used in outer layer 80 as discussed herein, then itis important to use THERMOLITE, THERMOLITE with foam or the Fosscomposite contracted of SSOFTHERM and acetate, polyester, acrylic or thelike with open cell foam needled into the base as layer 50 and 60 in allalpine liners and hiking applications. The Foss composite may bebi-polar in nature and may contain wood pulp or lyocel fibers. Again,the Outlast membrane or Frisby can be used in combination with the thirdmaterial 50, 60, especially in condition with THERMOLITE or the like.

The moisture vapor continues from the second foam material 30 throughthe mesh or spacer material 40 and on through the third exterior foam orTHERMOLITE material 50 or combinations if applied in layer 60. Themoisture vapors are then passed through waterproof/breathable membranelayer 70 if applied. The moisture vapors are absorbed intowaterproof/breathable membrane passed through to an outer layer offabric 80, as shown in FIG. 4. The waterproof/breathable membrane 70 canbe selected from a variety presently available on the market. Thoseunder the tradenames VAPEX 2000/Plus/Standard/1300, SECO-TEC, THINTECH,LAY-TEK and WITCOFLEX SUPER DRY FILM by Baxanden Chemicals (ahydrophilic membrane), and breathable membranes by Harrison Technologiesare currently being considered. However, the membranes currentlyconsidered to be the preferred ones are called TX-1540 (application byShawmut Mills). TX-1540 is intended to be an ultra-thin, skin friendly,moisture barrier that allows moisture vapors to escape while preventingoutside water from penetrating. The Outlast membrane or the FrisbyTechnologies can be used in combination with other membranes withencapsulation techniques, or with structurally knitted fabrics and canadjust to temperature changes. Of the various encapsulation techniques,the one practiced by Nextec is particularly advantageous.

Also shown in FIG. 4 is an optional protective rim or cuff 90,preferably made of a slow recovery foam (by FOAMEX, for example) aspacer product by Muller Textil or neoprene covered by LYCRA®. Cuff 90could also be made of a reticulated foam. The cuff is optional in allalpine and hiking boots. A pull tab 100, preferably made of nylon, isconnected to the protective rim 90. In adventure sports applications anabrasive protective material 110 is provided adjacent to a tongue 300.Another abrasive protective material 120 is provided around the heedportion of the shoe. Abrasive protective material 120 is supplied bySchoeller, DuPont®, or the like. the protective material is optional inall alpine liners.

The outer layer of fabric 80 of the lining system has 200 to 6000 denierstrength and is made waterproof by a membrane, a coating, encapsulationtechnology or by using structurally knitted, water repelling fabrics.Encapsulation technology is being utilized by a company called Nextec,Inc. or Toray, Inc. (a Japanese company or the like). Nextec Technologycan be combined with the Outlast membrane or Frisby Technology. TheOutlast membrane may be coated or laminated to the outer fabric. If theouter fabric is encapsulated then the outlast technology must be appliedto the fiber or fabric prior to encapsulation. The Frisby temperatureregulating molecules can be incorporated into the spaces between theencapsulated fibers and may be inserted at the time of encapsulation.The breathable membranes preserve the outer layer of fabric 80 andperform as a waterproof barrier for the runner orrider's liners. If theencapsulation technology is applied to the outer layer of fabric 80,then the breathable laminate membranes need not be used.

The outer layer 80 may be any of the following materials, eitherindividually or in combination. These materials include syntheticleathers, synthetic breathable fabrics, or the like, by Daewoo, Kevlar,and Cordura fabrics, by Schoeller, travis or the like, Kevlar, andtechnical fabrics by DuPont® and Toray, Cordura treated by encapsulationby Nectex, Toray, DuPont®, Travis, and the like, 4-ply Supplex, Cordurawaterproofed by the breathable membrane, F.L. fabric by Malden Mills,DERMIZAX by Toray, ENTRANT-GIL and WAXEY by Toray, GYMSTAR PLUS andTUFLEX-HR both by Unitika. The Corduras can be those made by others aswell. Nylon or polyester spacer meshes waterproofed by coating,encapsulation or film. There are primarily three ways of protectingouter layer 80, encapsulation, using a membrane, structurally knittingthe fabric to repel water or coating the fabrics with a waterproof film.Preferably, the outer layer 80 is a combination of one of theabove-mentioned materials with one of the following: the Outlast orFrisby Technologies and encapsulation by Nextec or the like, or theOutlast membrane or Frisby Technologies and the waterproof/breathablefabrics such as ENTRANT-GIL, DERMIZAX, TUFLEX, GYMSTAR or the like. TheOutlast membrane is laminated or coated to the outer fabric or woveninto the fabric or fibers, or the Frisby Technology embedded in theencapsulated outer fabric and then laminated to thewaterproof/breathable membrane, the Frisby or Outlast Technologies incombination with structurally knitted or woven waterproofed fabrics, orfinally the Frisby or Outlast Technologies in combination withENTRANT-GIL, DERMIZAX, TUFLEX, or GYMSTAR, nylon supplex or cordura,polyester, Kelvar or synthetic blends or the like. The outer fabrics inseveral performance categories may not apply either Frisby or OutlastTechnologies. The Frisby technology may also be in combination with anelastomeric technology preferable by Foxrun Technologies or abutting theouter fabric layer 80 in any of the open cell foams or a membrane byOutlast technologies may be laminated to the elastomeric compositeabutting the outer fabric layer 80. In fact phase change technology byFrisby, Outlast or Wisconsin Global Technologies may be applied to anylayer of elastomeric, foam or nonwoven where specified.

Elastomeric composite technology may be substituted in any area wherethere is a foam abutting nonwoven composite combination.

Selecting the proper materials depends upon the needs of each individualrunner or hiker or rider or skier's needs. The non-abrasive fabrics usedin the moisture transfer inner liner of the present invention greatlyreduces the possibility of trapped moisture, thereby protecting the footfrom fungus growth and any damage. The anti-fungal, anti-microbialpolypropylene (polyolefin) fabrics quickly remove moisture away from thefoot. Skin damage is minimized because the polypropylene fabric has asmooth, continuous surface or soft fleeced texture. This fabric alsoprevents bacterial build-up which can cause foot odor and fungus.Chemical ionization may be applied to polyolefin

The polyester looped terry blend is an excellent wicking fabric and canremove moisture rapidly when treated with a wetting agent or chemicalionization.

The anti-fungal, anti-microbial, DRI-LEX nylon fabrics, like thepolypropylene, is sanded and soft. The material is extremely comfortableand cool to the tough. Chemical ionization can be applied to nylon andnylon blends.

The polyester field sensor fabric works well with those individuals whoprefer high performance. The liner absorbs moisture immediately.

A polyester microfiber fabric is smooth to touch and wickable. A wettingagent may be added to assist in moisture transfer. Chemical ionizationcan be applied to nylon and nylon blends

Finally, a wool, cotton or polyester blend backed with polyester,acrylic or cotton or the like. Structurally knitted double faced andionized fabrics.

As a result of using this lining system, the runner, rider or hikercontinues to have a cooler, drier foot. The lightweight Kevlar,STARLITE, Cordura, DERMIZAX or the like outer liner materials are twiceas durable as the former heavyweight leathers, synthetic leathers andmaterials often used on the outer shell, functions as a flexible, highabrasive, breathable outer surface and aid in the moisture transfer andmay be in combination with synthetic leathers and nylon or polyesterspacer meshes products.

FIGS. 5(a) and 5(b) illustrate a sole portion 200 of a footbed insert.This removable footbed is constructed to remove moisture downward andout away from the runner or rider's foot. The inner lining materialabuts an open cell foam laminated to a nonwoven abutting a moldablespacer product preferably by Muller Textil. In some cases the nonwovenmay be removed. In extreme temperatures the Foss thermal compositeconstructed with Ssoftherm and a combination of one or more syntheticfibers is preferable. The synthetic fibers that may be blended with theSsofttherm include a combination of polyester, acrylic, lyocel blendsneedled together with and open foam may take the place of the nonwovenand open cell foam combination or may abut the open cell on one side andthe spacer product on the other side or the outer fabric. THERMOLITE orthe like may be an option to the Foss thermal composite and may beneedled together with an open cell foam. The footbed may be covered withCAMBRELLE DRI-LEX nylon, the Toray field sensor products or one of theselected inner lining materials or a nonwoven. The inserted hydrophilicopen cell and spacer fabric composite adds support and transfersmoisture downward. The bottom portion of the foam is preferably providedwith a non-woven top sheet as described earlier. The heel pocked foam orspacer fabric protects the back of the heel. This cushion protectorallows circulation in the heel. ComforMaxSport by DuPont®, ananti-microbial CAMBRELLE DRI-LEX nylon, Toray field sensor or one of theselected moisture transfer fabrics, or the like, covers a spacer fabricmaterial, a slow recovery foam or molded hydrophilic foam 220 thatsupports the arch and insures additional comfort for a runner in someapplications. This footbed insert is removable and when inserted abuts anonwoven thermal inside the liner. BA FIGS. 6, 7, and 8 illustrate thetongue 300 of the shoe in more detail. The tongue is designed to addfurther comfort and support. As shown in FIG. 8, an inner liner fabric310 of the tongue 300 is preferably one of the other inner linermaterials mentioned above, especially the field sensor by Toray,polypropylene, LYCRA® blend with INNOVA fiber, the polyester microfiber,the polyester looped terry or the fabrics by Malden Mills, looped terrypolypropylene blends or, polyester by Kronfli, Miliken or the like. Thisinner liner fabric 310 is preferably laminated to a structural supportfoam 320 and nonwoven. The nonwoven abuts a moldable spacer fabricfollowed by the nonwoven foot bed fabric. The foot bed is preferablymolded and removable. Preferably, the foam is an ⅛ inch or ¼ inch and isgermicidal, reticulated flexible polyester and open cell foam. The innerlining fabric may also be abutting an elastomeric composite or may bedirectly abutting a moldable spacer fabric and exterior materials. Ahydrophilic open cell or perforated foam 330 (also could be areticulated foam, or the like) abuts a structural support foam or spacerproduct 320. The hydrophilic perforated foam or spacer fabric 330 cantake the shape of the foot bones and protect the upper foot from damage.The structural support 320 can also be shaped to accommodate the footand protect the ankle bones. Optionally, a moldable spacer fabric byMuller, or the like, may also be used as portion 330. A moisturetransfer material 340 lies over the hydrophilic open cell or perforatedfoam 330. This moisture transfer material 340 is preferably made frommaterial known as aero-spacer DRI-LEX, which is manufactured by FaytexCorp, BIRDEYE nylon by Gilford Mills treated with or without transporttechnology, an aero-spacer fabric manufactured by Apex Mills, or awaterproof nylon or polyester blend or the like. The abutting exteriorfabrics may be either a nylon or polyester blend spacer mesh material orone of the selected exterior fabrics mentioned and can be coated with awaterproof coating. In one embodiment, the aero-spacer, exterior spacermeshes products or outer fabrics are in combinations with syntheticleathers. It should be understood that non-woven synthetic materials canalways be substituted for the aero-spacer DRI-LEX, spacer mesh productseven if not specifically mentioned in other parts of this disclosure.The spacer mesh products 340, in some hiking applications, is wrappedaround the outer edge of the tongue to allow moisture vapors travelingfrom the upper foot area to escape through moisture transfer material340 to the outer surface of the tongue 300. Material 340 also aids inproviding a softer edged tongue. Finally, an outer layer 350 may beadded in some hiking applications over a central portion of the material340. Another hydrophilic, molded foam (not shown), or slow recoveryform, moldable spacer fabric or hydrophilic foam, is shaped to fitbetween the outer layer 350 and material 340. In extreme adventure sportapplications the added protection may be required.

As shown in FIG. 6, outer layer 350, which can be a breathable syntheticleather (by Daewoo Corp. for example) or a Kevlar, or the like issurrounded by aero-spacer DRI-LEX 340, a substitute as mentioned aboveor a combination thereof. At the top of the tongue 300 an abrasivereflective grip fabric may be added for running and hiking applications(such as that manufactured by Schoeller and identified by the number6500, or the like), also shown in FIG. 4. Stitching is identified bynumeral 370. FIG. 7 illustrates a top portion of the tongue 300, andshows stitching 370 and the liner fabric 310.

The liners are preferably provided with a pull tab 100 as illustrated inFIGS. 4, 9, and 10 on the back of cuff 90 constructed of a slow recoveryfoam (by Rogers, or the like), moldable spacer fabric or neoprenecovered by LYCRA®. Optionally, cuff 90 can be omitted altogether. FIG. 9shows an opened up version of the liner looking from the back of theliner or hiking boot. Located just beneath the LYCRA® covered neoprenecuff or spacer fabric 90 is an abrasive grip fabric material 410, suchas manufactured by Schoeller, Inc., and referred to by the number 6500.Below material 410 is a reflective grip composite material 420. Anoption in the hiking application is a highly abrasive fabric 110 asshown in FIG. 4. Fabric 110 is preferable a Kevlar or STARLITE, or aCordura, or the like. Finally, outer shell fabric 80 is the same as thatshown in FIG. 4, and can be any of the fabrics listed previously inconnection with outer shell fabric 80. The nylon pull tab 100 allows therider's easily entree into the liner.

FIG. 10 shows the other side of the liner of FIG. 9. In FIG. 10, 510 canbe a ¼ inch moldable foam which has been punctured or a moldable spacerfabric or the like. 520 represents the combination of the flexible meshand foam (in case the moldable foam is not used as depicted), the outershell fabric. As in all of the figures, the arrows depict the flow ofmoisture. FIG. 11 illustrates the toe portion 400 of the liner.Preferably, the toe portion 400 is constructed with an inner liner 10,followed by a foam nonwoven composite abutting a thermal compositematerial 30, followed by a breathable membrane if used 60 and finallyfollowed by the outer fabric 70. Foam material 30 can either be a singlefoam, two foams, a foam, nonwoven, foam composite, a THERMOLITE, aTHERMOLITE and foam combination, Foss thermal composite with SSOFTHERMand synthetic fiber blends or any of these in combination with anon-woven top sheet (or a cellular elastomeric composite). Abrasive gripfabric is also shown. The breathable membrane is optional the shoe.

The 6500 high abrasive fabrics manufactured by Schoeller, Inc. or thelike are optionally located on the back of the cuff and the top of thetoe box and heel. The Kevlar and Cordura, STARLITE and Cordura fabricsprovide comfort and durability to the liners and are extremely strongand resistant to abrasion and allow for breathability and performance.

FIG. 12 illustrates a snowboard boot liner incorporating the liningsystem discussed above. The following elements of the snowboard boot areshown: numeral 610 represents a waterproof breathable synthetic leather,a Kevlar fabric (made by Schoeller, or a similar material), Schoeller,DuPont® & Toray or the like, Cordura or DERMIZAX by Toray; numeral 615represents materials similar to that of numeral 610, but can havedifferent colors for aesthetic purposes; numeral 630 represents a Kevlaror a material made by Schoeller, or the like, with the heel portionbeing synthetic rubber, EVA, or the like, manufactured by Daewoo;numeral 635 represents an inner moisture transfer material covering amolded breathable foam or spacer fabric; numeral 640 represents a Kevlaror Cordura material; numeral 650 represents some decorative piping madeof synthetic leather, stitching, polymer or the like; numeral 655represents a pull tab made of nylon or synthetic leather; numeral 660represents the base of the Boot which can be made of a syntheticpolyurethane; numeral 670 represents a reflective Kevlar back; andfinally, numeral 675 represents an optional sock that can be insertedinto the boot with the permanent liner or the removable liner insert ifdesired.

The sock 675 is made up of three layers. The first layer can be any ofthe inner liner materials discussed above. The second layer is a layerof foam or THERMOLITE, THERMOLITE with foam or the Foss thermalcomposite with a foam needled in or a combination thereof. The thirdlayer is a fabric such as moisture transfer polyester blend manufacturedby Deercreek fabrics, Menra Mills, or the like. Encapsulation technologycan also be applied to the third layer. Sock 675 can be used foradditional warmth and is removable, unlike the shoe liner and can beinserted into the all weather synthetic rubber or leather boot or acombination of leather and synthetic rubber boot, a snowboard boot, softalpine boot or alpine shell liner. The insert is preferable used in aboot where the inner liner is not removable. The three layers can beattached to one another by lamination, although mechanical bonding, orstitching, or ultrasonic bonding, can also be used.

FIG. 13 illustrates a running shoe 700 that is formed by the variouscombination of layers discussed above. The top portion of the shoe 700emphasizes the various layers that make up the shoe and should beinterpreted in the context of the discussion above regarding the variousoptions.

The microfiber technology disclosed above is rapidly developing andchanging and has greatly increased the potential for improvedperformance of such products such as running shoes and alpine boots,provided that they are properly utilized as in the present invention.These new products are part of rapidly developing fabric technology. Thepresent invention employs a combination of fabric, foam, nonwovens,moldable spacer materials and THERMOLITE or SSOFTHERM blended layerswith or without open cell foam needled into the layers, with or withoutbreathable membranes. Breathable membranes are optional in the runningor hiking shoe. Other options include structurally woven or knittedwaterproof fabrics, coated fabrics, or encapsulated outer fabrics insuch combinations that increase the performance of the products in whichthey are used as well as increasing breathability. The breathablemembrane is optional in all alpine, snowboard boot, hiking applicationsand removable insert sock liners rubber boots or the like. While thediscussion above has focused upon running and hiking shoes and snowboardand alpine boot liners, similar applications can be made with crosscountry boots, or in-line skates, protective gear, helmets, gloves,accessories and apparel with slight modifications. For example, in thecase of a cross country ski boot, the liner would preferably have awaterproofed outer fabric, attached to a synthetic rubber base.Encapsulation technology and membranes such as TX1540, WILCOFLEX DRYcombined with the Outlast technology from Gateway Technologies can beemployed. It is preferable to use Outlast or Frisby close to theindividual's foot in alpine, snowboard, or alpine cross country boots.Outlast or Frisby Technologies may also be added to any of the innerlining material listed. Otherwise, the liner could be very similar,although the use of the supportive mesh could be limited to certainareas. Adjustments in the breathable membrane would be made toaccommodate winter conditions and cosmetic changes could be applied tothe surface areas.

The following is a brief discussion of the variations that arepreferably employed for a running and hiking shoes and snowboard oralpine liners and the like. Similar names correspond to similar productsdiscussed above and are not described in further detail.

Alpine Boots

First, a liner for alpine boots is similar to in-line skate boots withmoldable spacer products and plastic mesh by Naltex used forhigh-performance boots. This liner would have the following layers ofmaterials (additional drawings for these applications are omitted inorder to be concise). The liner will be described in a sequence oflayers beginning with the innermost layer. The first layer is selectedfrom a group including field sensor technology by Toray, anti-microbial,anti-fungal, polypropylene INNOVA or ALPHA; DRI-LEX CAMBRELLE, or DRILEXDOE SKIN manufactured by Faytex Corp., looped poly terry by Kronfli,DRI-LEX/polyterry by Faytex, polypropylene or wool blends backed byanother fiber for example cotton or wool or the like by Coville,Cordura, polyester sueded or fleeced, moisture transfer materials, orMalden Mills polyester and blends thereof, or the like. A combination ofthese materials may also be employed depending upon the needs of anindividual skier. All fabrics may be chemical ionization.

Just in the case of the snowboard boot, the various layers can becombined by lamination, mechanical bonding, stitch bonding, ultrasonicbonding or a combination of these two. The second and third layers wouldinclude a foam that contacts the first layer and is a germicidal,reticulated foam or a hydrophilic, open-cell foam, such as AQUAZONE ORVPF, FOAMEX or COMFORTEMP by Frisby or the like. Alternatively, theselayers can be a cellular elastomeric composite which is one of theabove-mentioned foams backed by a non-woven apertured top sheet composedof wood pulp, polyester, rayon, cotton, or polypropylene, in a singleprocess. A foam nonwoven, foam, nonwoven composite may also be usedfollowed by a thermal composite if applicable.

The fourth layer is a hydrophilic, open cell (AQUAZONE or VPF), slowrecovery foam or flex-guard or a polyester spacer material (by Muller)or the like for support. In this case, AQUAZONE or VPF is laminated to aflat non-woven top sheet composed of wood pulp, rayon, cotton,polyester, lyocel, polypropylene which abuts a waterproof/breathablemembrane (fifth layer). If the flex-guard is used, it is followed byanother layer of AQUAZONE or VPF with a top sheet abutting thewaterproof/breathable membrane or the encapsulated outer fabrics. If thespacer material is used, it may or may not be molded to accommodate thefoot. The non-woven top sheet may be eliminated. The spacer materialwill be followed by either a waterproof membrane, an encapsulated orcoated fabric. The spacer material may alternatively be used in a numberof the boot layers in combination with a thermal composite, foam or afoam, nonwoven composite.

The fifth layer is a waterproof/breathable membrane which may be any oneof the following: Outlast membrane by Gateway Technologies incombination with SECO-TEX, No. TX1540 (laminated by Shawmut Mills),THINTECH, VAPEX 2000/1300 standard, Laytex and ENTRANT-GIL by Toray orthe like. The Outlast membrane by Gateway Technologies is in conjunctionwith one of the suggested breathable membranes or the like. Thelaminated or coated outlast membrane may also be combined with someencapsulated fibers and fabrics. The Frisby Technology may be embeddedin the preceding foam or THERMOLITE or MICROLOFT by DuPont®, but is notin combination with a breathable membrane. Frisby Technology can be usedin conjunction with structurally knitted waterproof fabrics, or with theencapsulation technology by Nectex, Toray or the like. Encapsulation byNextec combined with the Outlast Technologies is preferred. Ifencapsulation is employed, then the fourth layer preferably includesTHERMOLITE or a thermal foam composite inclusive of SSOFTHERM, a productby Foss Manufacturing, needled together with foam. If a non-removableliner is employed instead of a removable liner, a waterproof-breathablethin film can be used instead of encapsulation or awaterproof/breathable membrane.

The sixth and final layer in this removable shell liner may be Cordura,STARLITE, Tudor ¾ ply Supplex, Kevlar fabrics, DERMIZAX or encapsulatedfabric or any combination of them. Also, a waterproof breathable thinfilm coated fabric could be used.

Alpine Cross Country Boots

A liner for the alpine cross country boots is similar to the snowboardboot liner except the cross country boot does not have a sock liner, andthe foams (or THERMOLITE and foam) are thinner. This liner would includethe following. A first layer selected from a group includingpolypropylene, LYCRA® or wool backed by cotton, wool, or a rayon blendor an anti-microbial, anti-fungal INNOVA or ALPHA; sueded polyester;polyester field sensor; looped polyester terry; DRI-LEX DOESKIN or BABYKID by Faytex Corp.; polyester DRI-LEX Terry by Faytex; polyester spacerfabric by Malden; and polypropylene backed by cotton by Coville.

The second layer is a germicidal open cell hydrophilic foam. It may beCOMFORTEMP by Frisby or AQUAZONE or VPF with Frisby Technologies. Thisfoam can be provided with or without a non-woven top sheet. Thenon-woven top sheet can be selected from any of the materials previouslyspecified.

The third layer is a structural support foam or a moldable spacermaterial by Muller Textil. The foam may be a moldable hydrophilicAQUAZONE OR VPF. The heel and arch may also have a slow recovery foam orspacer product added for comfort. The thickness of the layer of foam orspacer fabric and THERMOLITE may vary for performance.

The fourth layer is a thin layer of THERMOLITE, the Foss foam thermalcomposite or AQUAZONE OR VPF or the like with a non-woven top sheet madeof wood pulp, rayon, cotton, polyester, or polypropylene. The fourthlayer may be optional in some performance categories.

The fifth layer is optionally, a waterproof/breathable membrane whichmay be any one of the following: SECO at Shawmut Mills, THINTECH, VAPEX2000/1300 standard, Laytex, breathable membranes by HarrisonTechnologies, or ENTRANT-GIL by Toray. The outlast membrane by GatewayTechnologies is employed for this layer. The outlast membrane can beused by itself, with another membrane or with encapsulation technologyon the outer fabric, such as Nextec, Toray or the like. FrisbyTechnology may also be applied in the open cell foam, or encapsulatedouter fabrics. COMFORTEMP by Frisby Technology may be used in someapplications. Alternatively, instead of the membrane, just encapsulationof the sixth layer can be performed to achieve similar results. Acombination of Outlast or Frisby and encapsulation fibers or fabrics byNextec or the like is preferred. If encapsulation is employed, then thefourth layer preferably includes THERMOLITE or the Foss Manufacturingthermal foam composite.

The sixth layer is one of the following fabrics. Note that if thesefabrics are encapsulated, the waterproof/breathable membrane in thefifth layer may not be needed in combination. These fabrics include thefollowing: Cordura; LYCRA® blends; STARLITE by Faytex Corp.; Kevlarfabric by Schoeller (14705, 6500, 13207, 13632, 65563, etc.); DuPont®and Toray or the like, Cordura 2000 by DuPont®, DERMIZAX and ENTRANT-GILby Toray, 3 or 4 ply Supplex; Mojave and Tudor nylon and polyesterblends by Travis; 6 ply Maxus nylon blends or the like; and syntheticleathers by Daewoo, Inc. or the like. These fabrics may be usedindividually or in combination.

The seventh layer is a LYCRA® covered neoprene, moldable spacer fabricor slow recovery foam or reticulated open cell foam ankle cuff.

The tongue for the alpine boot is similar to the tongue of the in-lineskate. The tongue of the cross country boot is similar to the snowboardboot. They can be constructed of AQUAZONE OR VPF molded foams with a topsheet or moldable spacer fabrics. A slow recovery foam can also be usedas specified with the snowboard boot. The inner fabric is one or more ofDRI-LEX Aero-spacer, polyester field sensor by Toray, polyester spacerby Malden, polypropylene, polar fleece, INNOVA or ALPHA or DRI-LEXDOESKIN, polyester sueded or fleeced or the like. The outer tonguefabrics are high abrasive fabrics Kevlar, STARLITE, or Schollar'sCorduras, 6500, DRI-LEX Aero-Spacer (or other Aero-spacer materials byFaytex, or the like, and breathable synthetic leathers by Daewoo, or thelike.

Hiking Boots

A liner for the hiking boot would include the following. The first layeris selected from a group including: polyester field sensor, looped polyterry, DRI-LEX by Faytex, DOE SKIN, BABY KID, CAMBRELLE by Faytex,anti-fungal, anti-microbial polypropylene fabrics, INNOVA or ALPHA,sueded polyester blends, COOL MAX or nylon blends, or the like. Anycombination of these moisture transfer fabrics can also be used.

The second layer is a cellular elastomeric composite or hydrophilic opencell AQUAZONE OR VPF foam or COMFORTEMP by Frisby. The Outlast membraneis optional in this layer. If a foam is used, a non-woven top sheetselected from previously mentioned materials can be attached as abacking.

The third layer is a molded hydrophilic AQUAZONE OR VPF backed by anaperture top sheet composed of cotton, polyester, polypropylene, lyocel,rayon, or wood pulp or the like. A moldable heel and ankle spacer fabricby Muller or the like may also be used in place of the third layer ofhydrophilic foam. A moldable spacer fabric or foam may be added aroundthe toe box and back cuff. A molded heel/ankle insert by Muller Textilis preferably also used.

The fourth layer may utilize a waterproof/breathable membrane which maybe any one of the following: Outlast membrane by Gateway Technologiescombined with SECO-TEX, TX1540 (distributed by Shawmut Mills), THINTECH,VAPEX 2000/1300 standard, Laytex, WILCOFLEX DRY or the like. The Outlasttechnology may also be used independently of the breathable membrane andmay also be coated to the outer fabric or fibers. Also, this membranelayer may be eliminated in some models depending upon the hiker's needs.Alternatively, instead of the membrane, encapsulation of the fifth layercan be performed to achieve similar results. If encapsulation isemployed, then the third layer is preferably AQUAZONE OR VPF or amoldable spacer fabric, or THERMOLITE or the thermal Foss composite. TheOutlast technology can be used in combination outer fabrics with orwithout encapsulation, such as by Nextec, or the like.

The fifth and last layer is a combination of one or more of thefollowing: Corduras; Supplex Nylon; STARLITE; Tudor; Kevlar; polyesternylon blends; and breathable synthetic leathers. Preferably, this layeris waterproofed by using encapsulation, waterproof films or coatings, orbreathable membranes, with or without the Outlast or FrisbyTechnologies.

Elastomeric composite technology may be substituted in any area wherethere is a foam abutting nonwoven combination.

Furthermore, the breathable liner according to the present inventioncould also be added to clothing such as shirts, pants, gloves, helmets,etc., by omitting elements such as the structural mesh and by adjustingthe number of foam material layers and their thickness. For example,clothing preferably has a wickable inner liner, followed by anelastomeric composite or a 1/16-⅛″ AQUAZONE OR VPF open cell foam whichmay be embedded with or without Frisby Technologies. A non-woven may ormay not be laminated to the foam. A breathable membrane abuts the foamor non-woven and is laminated to the outer fabric. The outer fabric maybe encapsulated, laminated to a breathable waterproof membrane, coatedwith a waterproof film, or structurally woven or knitted to repel water.Indeed, the amount of foam used can be reduced due to costconsideration, etc. Presently, this liner system is using THERMOLITE orthe thermal Ssoftherm product mechanically bonded to a needle punchedcomposite inclusive of open cell foam and is may use a polyester spunbonded filter products by Tangerding Vlitesstoffe, Vitafiber, or thelike to be used as an alternative to hydrophilic foam layers.

While the present invention has been described above in connection withthe preferred embodiments, one of ordinary skill in the art would beenabled by this disclosure to make various modifications to thedisclosed embodiments and still be within the scope and spirit of thepresent invention.

What is claimed is:
 1. A thermal nonwoven material comprised ofsynthetic fibers topically treated to have phase change reversibleenhanced thermal properties.